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Predictive maintenance
techniques: Part 1
Predictive maintenance basics
1.1
Maintenance philosophies
If we were to do a survey of the maintenance philosophies employed by different process
plants, we would notice quite a bit of similarity despite the vast variations in the nature of
their operations. These maintenance philosophies can usually be divided into four
different categories:
1.1.1
Figure 1.1
Maintenance Philosophies
Despite the many technical advances in the modern era, it is still not uncommon to find
production plants that operate with this maintenance philosophy.
1.1.2
1.1.3
1.1.4
1.2
Putting all this objectively, one can enumerate the benefits in the following way:
Increase in machine productivity: By implementing predictive maintenance,
it may be possible to virtually eliminate plant downtime due to unexpected
equipment failures.
Extend intervals between overhauls: This maintenance philosophy provides
information that allows scheduling maintenance activities on an as needed
basis.
Minimize the number of open, inspect and repair if necessary overhaul
routines: Predictive maintenance pinpoints specific defects and can thus
make maintenance work more focused, rather than investigating all possibilities
to detect problems.
Improve repair time: Since the specific equipment problems are known in
advance, maintenance work can be scheduled. This makes the maintenance work
faster and smoother. As machines are stopped before breakdowns occur, there is
virtually no secondary damage, thus reducing repair time.
Increase machine life: A well-maintained machine generally lasts longer.
Resources for repair can be properly planned: Prediction of equipment defects
reduces failure detection time, thus also failure reporting time, assigning of
personnel, obtaining the correct documentation, securing the necessary spares,
tooling and other items required for a repair.
Improve product quality: Often, the overall effect of improved maintenance
is improved product quality. For instance, vibration in paper machines has a
direct effect on the quality of the paper.
Save maintenance costs: Studies have shown that the implementation of a
proper maintenance plan results in average savings of 2025% in direct
maintenance costs in conjunction with twice this value in increased
production.
1.3
1.3.1
Maintenance strategy
The above-mentioned maintenance philosophies have their own advantages and
disadvantages and are implemented after carrying out a criticality analysis on the plant
equipment. Usually the criticality analysis categorizes the equipment as:
Critical
Essential
General purpose.
The critical equipment are broadly selected on the following basis:
If their failure can affect plant safety.
Machines that are essential for plant operation and where a shutdown will
curtail the production process.
Critical machines include unspared machinery trains and large horsepower
trains.
These machines have high capital cost, they are very expensive to repair
(e.g., high-speed turbomachinery) or take a long time to repair.
1.4
Figure 1.2
Predictive maintenance
In a similar way, defects that occur in a machine always exhibit a symptom in the form
of vibration or some other parameter. However, this may or may not be easily detected on
machinery systems with human perceptions.
It is here that predictive maintenance techniques come to assistance. These techniques
detect symptoms of the defects that have occurred in machines and assist in diagnosing
the exact defects that have occurred. In many cases, it is also possible to estimate the
severity of the defects.
The specific techniques used depend on the type of plant equipment, their impact on
production or other key parameters of plant operation. Of further importance are the goals
and objectives that the predictive maintenance program needs to achieve.
1.5
1.6
1.6.1
All rotating machines produce vibrations that are a function of the machine dynamics,
such as the alignment and balance of the rotating parts. Measuring the amplitude of
vibration at certain frequencies can provide valuable information about the accuracy of
shaft alignment and balance, the condition of bearings or gears, and the effect on the
machine due to resonance from the housings, piping and other structures.
Vibration measurement is an effective, non-intrusive method to monitor machine
condition during start-ups, shutdowns and normal operation. Vibration analysis is used
primarily on rotating equipment such as steam and gas turbines, pumps, motors,
compressors, paper machines, rolling mills, machine tools and gearboxes.
Recent advances in technology allow a limited analysis of reciprocating equipment such
as large diesel engines and reciprocating compressors. These machines also need other
techniques to fully monitor their operation.
A vibration analysis system usually consists of four basic parts:
1. Signal pickup(s), also called a transducer
2. A signal analyzer
3. Analysis software
4. A computer for data analysis and storage.
These basic parts can be configured to form a continuous online system, a periodic
analysis system using portable equipment, or a multiplexed system that samples a series
of transducers at predetermined time intervals.
Hard-wired and multiplexed systems are more expensive per measurement position.
The determination of which configuration would be more practical and suitable depends
on the critical nature of the equipment, and also on the importance of continuous or semicontinuous measurement data for that particular application.
1.6.2
1.6.3
2
Predictive maintenance
techniques: Part 2
Vibration basics
2.1
Figure 2.1
Spring-mass system
When an external force F moves the mass M forward, two things happen:
1. The spring is stretched.
2. The oil from the front of the piston moves to the back through the small
opening.
We can easily visualize that the force F has to overcome three things:
1. Inertia of the mass M.
2. Stiffness of the spring k.
3. Resistance due to forced flow of oil from the front to the back of the piston or,
in other words, the damping C of the dashpot mechanism.
All machines have the three fundamental properties that combine to determine how
the machine will react to the forces that cause vibrations, just like the spring-mass
system.
The three fundamental properties are:
(a) Mass (M)
(b) Stiffness (k)
(c) Damping (C).
These properties are the inherent characteristics of a machine or structure with which it
will resist or oppose vibration.
(a) Mass: Mass represents the inertia of a body to remain in its original state of
rest or motion. A force tries to bring about a change in this state of rest or
motion, which is resisted by the mass. It is measured in kg.
(b) Stiffness: There is a certain force required to bend or deflect a structure with
a certain distance. This measure of the force required to obtain a certain
deflection is called stiffness. It is measured in N/m.
(c) Damping: Once a force sets a part or structure into motion, the part or
structure will have inherent mechanisms to slow down the motion (velocity).
This characteristic to reduce the velocity of the motion is called damping. It is
measured in N/(m/s).
As mentioned above, the combined effects to restrain the effect of forces due to
mass, stiffness and damping determine how a system will respond to the given
external force.
Simply put, a defect in a machine brings about a vibratory movement. The mass,
stiffness and damping try to oppose the vibrations that are induced by the defect. If the
vibrations due to the defects are much larger than the net sum of the three restraining
characteristics, the amount of the resulting vibrations will be higher and the defect can be
detected.
2.2
System response
Consider a rotor system (Figure 2.2) that has a mass M supported between two bearings.
The rotor mass M is assumed as concentrated between the supported bearings; it contains
an unbalance mass (Mu) located at a fixed radius r and is rotating at an angular velocity
, where:
=2
rpm
60
Vibration basics 13
Figure 2.2
A rotor system response
However, in reality the restraining forces do not work in tandem. With changing
conditions, one factor may increase while the other may decrease. The net result can
display a variation in the sum of these forces.
This in turn varies the systems response (vibration levels) to exciting forces (defects
like unbalance that generate vibrations). Thus, the vibration caused by the unbalance will
be higher if the net sum of factors on the right-hand side of the equation is less than
unbalance force. In a similar way, it is possible that one may not experience any
vibrations at all if the net sum of the right-hand side factors becomes much larger than the
unbalance force.
2.3
What is vibration?
Vibration, very simply put, is the motion of a machine or its part back and forth from its
position of rest.
The most classical example is that of a body with mass M to which a spring with a
stiffness k is attached. Until a force is applied to the mass M and causes it to move, there
is no vibration.
Refer to Figure 2.3. By applying a force to the mass, the mass moves to the left,
compressing the spring. When the mass is released, it moves back to its neutral position
and then travels further right until the spring tension stops the mass. The mass then turns
around and begins to travel leftwards again. It again crosses the neutral position and
reaches the left limit. This motion can theoretically continue endlessly if there is no
damping in the system and no external effects (such as friction).
This motion is called vibration.
Figure 2.3
The nature of vibration
2.4
Vibration basics 15
Figure 2.4
Simple harmonic wave locus of spring-mass motion with respect to time
As the mass travels up and down, the velocity of the travel changes from zero to a
maximum. Velocity can be obtained by time differentiating the displacement equation:
dX
= X 0 cos t
dt
Similarly, the acceleration of the mass also varies and can be obtained by differentiating
the velocity equation:
d (velocity)
acceleration =
= X 0 2 sin t
dt
velocity =
Figure 2.5
Waveform of acceleration, velocity and displacement of mass in simple harmonic motion
2.4.1
Wave fundamentals
Terms such as cycle, frequency, wavelength, amplitude and phase are frequently used
when describing waveforms. We will now discuss these terms and others in detail as they
are also used to describe vibration wave propagation.
We will also discuss waveforms, harmonics, Fourier transforms and overall vibration
values, as these are concepts connected to machine diagnostics using vibration analysis.
In Figure 2.6, waves 1 and 2 have equal frequencies and wavelengths but different
amplitudes. The reference line (line of zero displacement) is the position at which a
particle of matter would have been if it were not disturbed by the wave motion.
Figure 2.6
Comparison of waves with different amplitudes
2.4.2
Frequency (cycle)
At point E, the wave begins to repeat with a second cycle, which is completed at point I, a
third cycle at point M, etc. The peak of the positive alternation (maximum value above
the line) is sometimes referred to as the top or crest, and the peak of the negative
alternation (maximum value below the line) is sometimes called the bottom or trough, as
shown in Figure 2.6. Therefore, one cycle has one crest and one trough.
2.4.3
Wavelength
A wavelength is the distance in space occupied by one cycle of a transverse wave at any
given instant. If the wave could be frozen and measured, the wavelength would be the
distance from the leading edge of one cycle to the corresponding point on the next cycle.
Wavelengths vary from a few hundredths of an inch at extremely high frequencies to
many miles at extremely low frequencies, depending on the medium. In Figure 2.6 (wave 1),
the distance between A and E, or B and F, etc., is one wavelength. The Greek letter
(lambda) is commonly used to signify wavelength.
2.4.4
Amplitude
Two waves may have the same wavelength, but the crest of one may rise higher above the
reference line than the crest of the other, for instance waves 1 and 2 in Figure 2.6. The height
Vibration basics 17
of a wave crest above the reference line is called the amplitude of the wave. The amplitude of
a wave gives a relative indication of the amount of energy the wave transmits. A continuous
series of waves, such as A through Q, having the same amplitude and wavelength, is
called a train of waves or wave train.
2.4.5
2.4.6
Phase
If we consider the two waves as depicted in Figure 2.7, we find that the waves are
identical in amplitude and frequency but a distance of T/4 offsets the crests of the waves.
This lag of time is called the phase lag and is measured by the phase angle.
Figure 2.7
Phase relationship between two similar waves
A time lag of T is a phase angle of 360, thus a time lag of T/4 will be a phase
angle of 90.
In this case we would normally describe the two waves as out of phase by 90.
2.4.7
Waveforms
We have seen earlier, under the topic nature of vibrations, that displacement, velocity and
acceleration of a spring-mass system in motion can be represented by sine and cosine
waves. The waveform is a visual representation (or graph) of the instantaneous value of
the motion plotted against time.
2.5
Harmonics
Figure 2.8 depicts many interesting waveforms. Let us presume that displacement is
represented on the Y-axis. Since it is a representation vs time, the X-axis will be the time
scale of 1 s.
Figure 2.8
An interesting waveform
The first wave that we should observe is the [1] wave. It is represented by one
cycle. As the time scale is 1 s, it has a frequency of 1 Hz.
The next wave to be considered is the [3] wave. It can be seen that it has three
cycles in the same period of the first wave. Thus, it has a frequency of 3 Hz.
Third is the [5] wave. Here five cycles can be traced, and it thus has a frequency
of 5 Hz.
Next is the [7] wave. It has seven cycles and therefore a frequency of 7 Hz.
The [9] wave is next with nine cycles and it will have a frequency of 9 Hz.
In this way an odd series (1,3,5,7,9) of the waves can be observed in the figure. Such a
series is called the odd harmonics of the fundamental frequency.
If we were to see waveforms with frequencies of 1,2,3,4,5 . . . Hz, then they would be
the harmonics of the first wave of 1 Hz. The first wave of the series is usually designated
as the wave with the fundamental frequency.
Coming back to the figure, it is noticed that if the fundamental waveforms with odd
harmonics are added up, the resultant wave seen on the figure incidentally looks like a
square waveform, which is more complex.
If a series of sinusoidal waveforms can be added to form a complex waveform, then is
the reverse possible? It is possible and this is a widely used technique called the Fourier
Vibration basics 19
2.5.1
Fourier analysis
Fourier analysis is another term for the transformation of a time waveform (Figure 2.9) into
a spectrum of amplitude vs frequency values. Fourier analysis is sometimes referred to as
spectrum analysis, and can be done with a fast Fourier transform (FFT) analyzer.
Figure 2.9
A Fourier transform of the square waveform
2.5.2
Overall amplitude
We have seen how a square waveform looks like in the time domain. The waveform is a
representation of instantaneous amplitude of displacement, velocity or acceleration with
respect to time.
The overall level of vibration of a machine is a measure of the total vibration amplitude
over a wide range of frequencies, and can be expressed in acceleration, velocity or
displacement (Figure 2.10).
The overall vibration level can be measured with an analog vibration meter, or it can be
calculated from the vibration spectrum by adding all the amplitude values from the
spectrum over a certain frequency range.
When comparing overall vibration levels, it is important to make sure they were
calculated over the same frequency range.
2.5.3
Vibration terminology
Vibration displacement (peak to peak)
The total distance travelled by a vibrating part, from one extreme limit of travel to the
other extreme limit of travel is referred to as the peak to peak displacement.
In SI units this is usually measured in microns (1/1000th of a millimeter).
In imperial units it is measured in mils (milli inches 1/1000th of an inch).
Displacement is sometimes referred to only as peak (ISO 2372), which is half of
peak to peak.
Figure 2.10
Overall vibration plot of velocity
Vibration basics 21
maximum value, the acceleration drops to zero and again continues to rise to its
maximum value at the other extreme limit of travel.
Acceleration is normally expressed in g, which is the acceleration produced by the force
of gravity at the surface of the earth. The value of g is 9.80665 m/s2, 32.1739 ft/s2 or
386.087 in./s2.
Displacement, velocity, acceleration which should be used?
The displacement, velocity and acceleration characteristics of vibration are measured to
determine the severity of the vibration and these are often referred to as the amplitude of
the vibration.
In terms of the operation of the machine, the vibration amplitude is the first indicator to
indicate how good or bad the condition of the machine may be. Generally, greater
vibration amplitudes correspond to higher levels of machinery defects.
Since the vibration amplitude can be either displacement, velocity or acceleration,
the obvious question is, which parameter should be used to monitor the machine
condition?
The relationship between acceleration, velocity and displacement with respect to
vibration amplitude and machinery health redefines the measurement and data analysis
techniques that should be used. Motion below 10 Hz (600 cpm) produces very little
vibration in terms of acceleration, moderate vibration in terms of velocity and relatively
large vibrations in terms of displacement (see Figure 2.11). Hence, displacement is used
in this range.
Figure 2.11
Relationship between displacement, velocity and acceleration at constant velocity. EU, engineering units
In the high frequency range, acceleration values yield more significant values than velocity
or displacement. Hence, for frequencies over 1000 Hz (60 kcpm) or 1500 Hz (90 kcpm),
the preferred measurement unit for vibration is acceleration.
It is generally accepted that between 10 Hz (600 cpm) and 1000 Hz (60 kcpm) velocity
gives a good indication of the severity of vibration, and above 1000 Hz (60 kcpm),
acceleration is the only good indicator.
Since the majority of general rotating machinery (and their defects) operate in the
101000 Hz range, velocity is commonly used for vibration measurement and
analysis.
2.5.4
Figure 2.12
Machinery fault detection
Each of these rotating parts is further comprised of simple components such as:
When these components operate continuously at high speeds, wear and failure is
imminent. When defects develop in these components, they give rise to higher vibration
levels.
With few exceptions, mechanical defects in a machine cause high vibration levels.
Common defects that cause high vibrations levels in machines are:
(a)
(b)
(c)
(d)
(e)
Vibration basics 23
(f)
(g)
(h)
(i)
(j)
(k)
(l)
Torque variations
Electromagnetic forces
Aerodynamic forces
Hydraulic forces
Looseness
Rubbing
Resonance.
To generalize the above list, it can be stated that whenever either one or more parts are
unbalanced, misaligned, loose, eccentric, out of tolerance dimensionally, damaged or
reacting to some external force, higher vibration levels will occur.
Some of the common defects are shown in Figure 2.12. The vibrations caused by the
defects occur at specific vibration frequencies, which are characteristic of the components,
their operation, assembly and wear. The vibration amplitudes at particular frequencies are
indicative of the severity of the defects.
Vibration analysis aims to correlate the vibration response of the system with specific
defects that occur in the machinery, its components, trains or even in mechanical
structures.
2.6
2.6.1
ISO 2372
The most widely used standard as an indicator of vibration severity is ISO 2372 (BS
4675). The standard can be used to determine acceptable vibration levels for various
classes of machinery. Thus, to use this ISO standard, it is necessary to first classify the
machine of interest. Reading across the chart we can correlate the severity of the machine
condition with vibration. The standard uses the parameter of velocity-rms to indicate
severity. The letters A, B, C and D as seen in Figure 2.13, classify the severity.
Figure 2.13
Class I Individual parts of engines and machines integrally connected with a complete
machine in its normal operating condition (production electrical motors of up to 15 kW
are typical examples of machines in this category).
Class II Medium-sized machines (typically electrical motors with 1575 kW output)
without special foundations, rigidly mounted engines or machines (up to 300 kW) on
special foundations.
Class III Large prime movers and other large machines with rotating masses mounted
on rigid and heavy foundations, which are relatively stiff in the direction of vibration.
Class IV Large prime movers and other large machines with rotating masses mounted
on foundations, which are relatively soft in the direction of vibration measurement (for
example turbogenerator sets, especially those with lightweight substructures).
American Petroleum Institute (API specification)
The American Petroleum Institute (API) has set forth a number of specifications dealing
with turbomachines used in the petroleum industry. Some of the specifications that have
been prepared include API-610, API-611, API-612, API-613, API-616 and API-617.
These specifications mainly deal with the many aspects of machinery design, installation,
performance and support systems. However, there are also specifications for rotor balance
quality, rotor dynamics and vibration tolerances.
API standards have developed limits for casing as well as shaft vibrations (Figure 2.14).
The API specification on vibration limits for turbo machines is widely accepted and
followed with apparently good results.
The API standard specifies that the maximum allowable vibration displacement of a
shaft measured in mils (milli-inches = 0.001 inch = 0.0254 mm) peakpeak shall not be
greater than 2.0 mils or (12 000/N)1/2, where N is speed of the machine, whichever
is less.
Vibration basics 25
Figure 2.14
Vibration limits API-610 centrifugal pumps in refinery service
2.6.2
Figure 2.15
General machinery severity chart
Vibration basics 27
The chart applies to machines that are rigidly mounted or bolted to a fairly rigid
foundation. Machines mounted on resilient vibration isolators such as coil springs or
rubber pads will generally have higher amplitudes of vibration compared to rigidly mounted
machines.
A general rule is to allow twice as much vibration for a machine mounted on isolators.
High-frequency vibrations should not be subjected to the above criteria.
General vibration acceleration severity chart
The general vibration acceleration severity chart is used in cases where machinery
vibration is measured in units of acceleration (g-peak) (see Figure 2.16).
Constant vibration velocity lines are included on the chart to provide a basis for
comparison, and it can be noted that for vibration frequencies below 60 000 cpm (1000 Hz),
the lines that divide the severity regions are of a relatively constant velocity. However,
above this limit, the severity regions are defined by nearly constant acceleration values.
Since the severity of vibration acceleration depends on frequency, only filtered
acceleration readings can be applied to the chart.
Figure 2.16
Vibration acceleration severity chart IRD mechanalysis
Type of Machine
Grinders
Thread grinder
Profile or contour grinder
Cylindrical grinder
Surface grinder (vertical reading)
Gardener or besly type
Centerless
Boring machine
Lathe
A rising trend is of great concern even when the velocity values as per the standard are
still in Good range. Similarly, a machine operating for years with velocity values in the
Not acceptable range is not a problem if there is no rising trend.
Those who have been working on the shop floor for a long time will agree that even
two similar machines built simultaneously by one manufacturer can have vastly different
vibration levels and yet operate continuously without any problems. One has to accept the
limitations of these standards, which cannot be applied to a wide range of complex
machines. Some machines such as hammer mills or rock and coal crushers will inherently
have higher levels of vibration anyway.
Therefore, the values provided by these guides should be used only if experience,
maintenance records and history proved them to be valid.